US20110275737A1 - Artificial chip having the texture of natural granite and artificial marble including the same - Google Patents

Artificial chip having the texture of natural granite and artificial marble including the same Download PDF

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Publication number
US20110275737A1
US20110275737A1 US13/144,497 US201013144497A US2011275737A1 US 20110275737 A1 US20110275737 A1 US 20110275737A1 US 201013144497 A US201013144497 A US 201013144497A US 2011275737 A1 US2011275737 A1 US 2011275737A1
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United States
Prior art keywords
artificial
chip
weight
parts
base resin
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Abandoned
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US13/144,497
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English (en)
Inventor
Hang Young KIM
Jae Ho Oh
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LX Hausys Ltd
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LG Hausys Ltd
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Assigned to LG HAUSYS, LTD. reassignment LG HAUSYS, LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: KIM, HANG YOUNG, OH, JAE HO
Publication of US20110275737A1 publication Critical patent/US20110275737A1/en
Abandoned legal-status Critical Current

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    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
    • C04B26/02—Macromolecular compounds
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B18/00—Use of agglomerated or waste materials or refuse as fillers for mortars, concrete or artificial stone; Treatment of agglomerated or waste materials or refuse, specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B18/02—Agglomerated materials, e.g. artificial aggregates
    • C04B18/022—Agglomerated materials, e.g. artificial aggregates agglomerated by an organic binder
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B24/00—Use of organic materials as active ingredients for mortars, concrete or artificial stone, e.g. plasticisers
    • C04B24/24—Macromolecular compounds
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2103/00—Function or property of ingredients for mortars, concrete or artificial stone
    • C04B2103/54—Pigments; Dyes
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/54—Substitutes for natural stone, artistic materials or the like
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/54—Substitutes for natural stone, artistic materials or the like
    • C04B2111/542—Artificial natural stone
    • C04B2111/545—Artificial marble
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L33/00—Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides or nitriles thereof; Compositions of derivatives of such polymers
    • C08L33/04—Homopolymers or copolymers of esters
    • C08L33/06—Homopolymers or copolymers of esters of esters containing only carbon, hydrogen and oxygen, which oxygen atoms are present only as part of the carboxyl radical

Definitions

  • the present invention relates to an artificial chip having the texture of natural granite and an artificial marble prepared using the same. More particularly, the present invention relates to an artificial chip having the texture of natural granite and artificial marble including the same, in which the artificial chip is manufactured by mixing a core part of a transparent chip or a general chip with a base resin and forming artificial marble by mixing with a base resin.
  • artificial marble is widely used as an interior building material and is employed in various applications such as kitchen sinks, washbasins, wall materials in stores, and the like, due to excellent texture, aesthetics, processibility, and weather resistance.
  • Artificial marble collectively refers to artificial composites exhibiting the texture of natural marble manufactured by mixing natural stone powder or minerals with a resin component or cement and adding pigments and additives.
  • the artificial marble is classified into acrylic materials, unsaturated polyester materials, and engineered stone materials.
  • acrylic artificial marble is used for various purposes due to transparency of resin and high-quality texture.
  • Engineered stone artificial marble refers to artificial marble produced using natural stone powder, quartz, glass and aluminum as main ingredients and about 10% or less by weight of resin.
  • Korean Patent No. 505185 discloses a method of manufacturing artificial marble that reproduces the multicolor patterns of natural marble by repeating a process of forming a printing layer through alternately screen printing different colors of paint to one side of a glass board and hardening the printed layer a plurality of times.
  • the printed layer is formed by screen printing and is then hardened at 150 to 200° C. for 15 to 30 minutes.
  • Korean Patent Laid-open Publication No. 2005-81298 discloses a process of manufacturing artificial marble, which includes forming a multicolor pattern-printed layer on a rear side of transparent glass using a pigment through silkscreen printing, drying the layer at 130 to 180° C.
  • One aspect of the present invention is to provide artificial marble having a texture of natural granite manufactured by forming an artificial chip board having the texture of natural granite using a core part and a base resin, crushing the board into artificial chips having the texture of natural granite that include different colors and sizes of chips, and mixing the artificial chips with a base resin into artificial marble exhibiting various colors in one chip.
  • Another aspect of the present invention is to provide an artificial chip and a method of manufacturing the same, in which a base resin is used in a smaller amount than 25 parts by weight used in a conventional artificial chip manufacturing method without using an inorganic filler or by minimizing use of the inorganic filler to be far less than about 40 parts by weight in the art.
  • the present invention provides an artificial chip having the texture of natural granite includes 80 to 95 parts by weight of a core part and 5 to 20 parts by weight of a base resin, and artificial marble including the same.
  • artificial marble includes core parts having different sizes in one chip to exhibit a variety of colors through one chip, thereby manufacturing artificial marble having the texture of natural granite.
  • the amount of artificial chips having the texture of natural granite is increased than the amount of base resin, so that the base resin serves as a pigment while preventing cracking of the artificial chips.
  • FIG. 1 is a configuration view of an artificial chip having the texture of natural granite in accordance with an exemplary embodiment of the present invention
  • FIG. 2 is a configuration view of artificial marble having the texture of natural granite in accordance with an exemplary embodiment of the present invention
  • FIG. 3 is a configuration view of artificial marble having the texture of natural granite via surface treatment in accordance with an exemplary embodiment of the present invention
  • FIG. 4 is a photograph of artificial marble manufactured by a method in accordance with an exemplary embodiment of the present invention.
  • FIG. 5 is an enlarged view of Circle A of FIG. 4 .
  • an artificial chip having the texture of natural granite includes 80 to 95 parts by weight of a core part and 5 to 20 parts by weight of a base resin.
  • a method of manufacturing an artificial chip having the texture of natural granite includes: (a) mixing 80 to 95 parts by weight of a core part with 5 to 20 parts by weight of a base resin slurry; (b) pressing, specifically heat pressing, the mixture into an artificial chip board having the texture of natural granite in a plate shape; and (c) crushing the artificial chip board having the texture of natural granite.
  • artificial marble includes an artificial chip having the texture of natural granite.
  • a method of manufacturing artificial marble includes: (a) mixing 80 to 95 parts by weight of an artificial chip having the texture of natural granite with 5 to 20 parts by weight of a base resin slurry; and (b) pressing, specifically heat pressing, the mixture into artificial marble having a plate shape.
  • An artificial chip having the texture of natural granite according to the invention is included in artificial marble to simulate the texture of natural granite and may include, without being limited to, 80 to 95 parts by weight of a core part and 5 to 20 parts by weight, preferably 13 to 18 parts by weight of a base resin.
  • the artificial chip having the texture of natural granite has a specific gravity of 1.4 to 1.8, preferably 1.5 to 1.7.
  • the core part may be formed of any chip having various sizes and colors which is generally used to manufacture artificial marble in the art and include, without being limited to, a transparent chip, a general chip, or a mixture thereof.
  • the transparent chip means a resin chip having a total light transmittance of at least 80%.
  • the general chip means a resin chip generally used to manufacture artificial marble or the like in the art, specifically opaque resin chips including at least one selected from the group consisting of acrylic resin, unsaturated polyester resins, epoxy resins, polyvinyl chloride, polystyrene, polycarbonate, polyethylene terephthalate, and a styrene-methyl methacrylate copolymer.
  • the core part may have a size of 0.1 to 5 mm.
  • the base resin forming the artificial chip having the texture of natural granite may include, but is not limited thereto, at least one selected from the group consisting of acrylic resins, unsaturated polyester resins, epoxy resins, polyvinyl chloride, polystyrene, polycarbonate, polyethylene terephthalate, and styrene-methyl methacrylate copolymers.
  • the base resin forming the artificial chip may further include 1 to 15 parts by weight of at least one material selected from the group consisting of pearl, a pigment, a curing agent, and additives.
  • the pearl, the pigment, the curing agent, and the additive are not specifically limited and may include any material generally used to manufacture artificial marble in the art.
  • examples of the additives may include at least one selected from silicone or non-silicone antifoaming agents; silane or titanate coupling agents including trimethoxy silane as a main component; phenyl salicylate, benzophenone, benzotriazole, nickel derivatives or radical inhibitor-type UV absorbers; halogen, phosphorus or inorganic metal frame retardants; stearic or silicone release agents; catechol and hydroquinone polymerization inhibitors; phenolic, amine, quinone, sulfur or phosphorus antioxidants; diacrylate cross-linkers; and mercaptan chain transfer agents.
  • the base resin forming the artificial chip may further include 20 parts by weight or less, preferably 10 parts by weight or less, and more preferably 5 parts by weight or less of inorganic fillers.
  • inorganic fillers are not necessarily included in the base resin, a minimum amount of inorganic fillers may be used.
  • Proper examples of inorganic fillers may include calcium carbonate, aluminum hydroxide, silica, alumina, barium sulfate, magnesium hydroxide, or the like.
  • inorganic powder having a size of 1 to 100 ⁇ m may be used.
  • the artificial chip having the texture of natural granite is manufactured by mixing a core part and a base resin slurry, pressing the mixture into an artificial chip board, and crushing the board.
  • the method includes: (a) mixing 80 to 95 parts by weight of the core part with 5 to 20 parts by weight of the base resin slurry; (b) pressing, specifically heat pressing the mixture into an artificial chip board having the texture of natural granite in a plate shape; and (c) crushing the artificial chip board having the texture of natural granite.
  • the heat pressing means heat pressing and pressurizing at 80 to 150° C. and a pressure of 20 to 80 Kgf/cm 2 .
  • the artificial chip having the texture of natural granite manufactured through crushing the artificial chip board having the texture of natural granite may have a size of 1 to 15 mm. If the size of the artificial chip having the texture of natural granite is too large, a final product, i.e., artificial marble produced into a plate, has a limited thickness, cracks may be formed between the artificial chip and the base, and fluidity may be affected.
  • the size of the artificial chip is 15 mm or less, relatively small chips may be more advantageously used than relatively large chips. Further, in order to exhibit various patterns, artificial chips having various sizes are manufactured and then mixtures thereof may be used to manufacture artificial marble.
  • the core part forming the artificial chip having the texture of natural granite may be formed of any chip having various sizes and colors which is generally used to manufacture artificial marble in the art and include, without being limited to, a transparent chip, a general chip, or a mixture thereof.
  • the transparent chip means a resin chip having a total light transmittance of at least 80%.
  • the general chip means a resin chip, which is generally used to manufacture artificial marble or the like in the art, specifically, opaque resin chips including at least one selected from the group consisting of acrylic resins, unsaturated polyester resins, epoxy resins, polyvinyl chloride, polystyrene, polycarbonate, polyethylene terephthalate, and styrene-methyl methacrylate copolymers.
  • the core part may have a size of 0.1 to 5 mm.
  • the base resin slurry means a slurry-type composition including a monomer and/or a polymer of a base resin to manufacture an artificial chip having the texture of natural granite.
  • the base resin may include at least one selected from the group consisting of acrylic resins, unsaturated polyester resins, epoxy resins, polyvinyl chloride, polystyrene, polycarbonate, polyethylene terephthalate, and styrene-methyl methacrylate copolymers, without being limited thereto.
  • the base resin for forming the artificial chip may further include 1 to 15 parts by weight of at least one material selected from the group consisting of pearl, a pigment, a curing agent, and additives.
  • the pearl, the pigment, the curing agent, and the additives are not specifically limited and may include any material generally used to manufacture artificial marble in the art.
  • examples of the additives may include at least one selected from silicone or non-silicone antifoaming agents; silane or titanate coupling agents including trimethoxy silane as a main component; phenyl salicylate, benzophenone, benzotriazole, nickel derivatives or radical inhibiting UV absorbers; halogen, phosphorus or inorganic metal frame retardants; stearic or silicone release agents; catechol and hydroquinone polymerization inhibitors; phenolic, amine, quinone, sulfur or phosphorus antioxidants; diacrylate cross-linkers; and mercaptan chain transfer agents.
  • the base resin may further include 20 parts by weight or less, preferably 10 parts by weight or less, and more preferably 5 parts by weight or less of inorganic fillers.
  • the base resin may be a slurry type base resin.
  • the base resin slurry may include 100 parts by weight of a base resin syrup, 0 to 30 parts by weight of inorganic fillers, 0.2 to 5 parts by weight of a cross-linker, 0.2 to 3.0 parts by weight of a cross-linking accelerator, and 0.1 to 5 parts by weight of a pigment.
  • the base resin, the inorganic filler, the cross-linker, the cross-linking accelerator, and the pigment, which form the base resin slurry may be any material generally used in the art.
  • the base resin syrup for the base resin slurry is resin syrup in which monomers of the base resin and polymers thereof are dissolved.
  • the cross-linker may include multifunctional methacrylates, for example, ethylene glycol dimethacrylate, propylene glycol dimethacrylate, glycerol trimethacrylate, trimethylolpropane trimethacylate, and bisphenol-A dimethacrylate.
  • multifunctional methacrylates for example, ethylene glycol dimethacrylate, propylene glycol dimethacrylate, glycerol trimethacrylate, trimethylolpropane trimethacylate, and bisphenol-A dimethacrylate.
  • a method of manufacturing artificial marble includes: a) mixing 80 to 95 parts by weight of an artificial chip having the texture of natural granite with 5 to 20 parts by weight of a base resin slurry; and (b) pressing, specifically heat pressing the mixture into an artificial marble board having a plate shape.
  • the artificial chip having the texture of natural granite may have a size of 0.5 to 1.5 mm, and the heat pressing means heat pressing and pressurizing at 80 to 150° C. and a pressure of 20 to 80 Kgf/cm 2 .
  • the mixing process (a) 5 to 15 parts by weight of a general chip may further be added as needed.
  • the general chip may have a size of 0.1 to 20 mm.
  • the general chip means a resin chip generally used to manufacture artificial marble or the like in the art, specifically resin chips including at least one selected from the group consisting of acrylic resin, unsaturated polyester resins, epoxy resins, polyvinyl chloride, polystyrene, polycarbonate, polyethylene terephthalate, and a styrene-methyl methacrylate copolymer.
  • the base resin slurry means a slurry-type composition including a monomer and/or a polymer of a base resin to manufacture artificial marble.
  • the base resin may include at least one selected from the group consisting of acrylic resin, unsaturated polyester resins, epoxy resins, polyvinyl chloride, polystyrene, polycarbonate, polyethylene terephthalate, and a styrene-methyl methacrylate copolymer, without being limited thereto.
  • the base resin may further include 1 to 15 parts by weight of at least one material selected from the group consisting of pearl, a pigment, a curing agent, and additives.
  • the pearl, the pigment, the curing agent, and the additive are not specifically limited and may include any material generally used to manufacture artificial marble in the art.
  • examples of the additives may include at least one selected from silicone or non-silicone antifoaming agents; silane or titanate coupling agents including trimethoxy silane as a main component; phenyl salicylate, benzophenone, benzotriazole, nickel derivatives or radical inhibiting UV absorbers; halogen, phosphorus or inorganic metal frame retardants; stearic or silicone release agents; catechol and hydroquinone polymerization inhibitors; phenolic, amine, quinone, sulfur or phosphorus antioxidants; diacrylate cross-linkers; and mercaptan chain transfer agents.
  • the base resin may further include 20 parts by weight or less, preferably 10 parts by weight or less, and more preferably 5 parts by weight or less of inorganic fillers.
  • the base resin may be a slurry type base resin.
  • the base resin slurry may include 100 parts by weight of a base resin syrup, 0 to 30 parts by weight of inorganic fillers, 0.2 to 5 parts by weight of a cross-linker, 0.2 to 3.0 parts by weight of a cross-linking accelerator, and 0.1 to 5 parts by weight of a pigment.
  • the base resin, the inorganic filler, the cross-linker, the cross-linking accelerator, and the pigment, which form the base resin slurry may be any material generally used in the art.
  • the base resin syrup for the base resin slurry is resin syrup in which monomers of the base resin and polymers thereof are dissolved.
  • the cross-linker may include multifunctional methacrylates, for example, ethylene glycol dimethacrylate, propylene glycol dimethacrylate, glycerol trimethacrylate, trimethylolpropane trimethacrylate, and bisphenol-A dimethacrylate.
  • multifunctional methacrylates for example, ethylene glycol dimethacrylate, propylene glycol dimethacrylate, glycerol trimethacrylate, trimethylolpropane trimethacrylate, and bisphenol-A dimethacrylate.
  • a chip 800 parts by weight of a chip (specific gravity: 1.64) as a core part formed of a transparent, crushed and cured halogenated epoxy material obtained by curing a mixture of epoxy resin (YDB 400, Kukdo Chemical Co., Ltd., Korea) and an amine curing agent (D-230, IPDA, Kukdo Chemical Co., Ltd., Korea) was mixed with a base resin containing 150 parts by weight of an acrylic resin, 6 parts by weight of pearl, 1 part by weight of tert-butyl perbenzoate (TBPB, Luperox P, ATOFINA) as a curing agent, and 5 parts by weight of additives of a diacrylate cross-linker (SR-231, Satomer) and a mercaptan chain transfer agent (normal dodecyl mercaptan, Chemos, Germany).
  • SR-231 diacrylate cross-linker
  • a mercaptan chain transfer agent normal dodecyl mercaptan, Chemos, Germany
  • the mixture was heat-pressed at 100° C. and at about 70 Kgf/m 2 to prepare an artificial chip board having the texture of natural granite in a plate shape.
  • the artificial chip board was crushed into chips having a diameter of 0.5 to 15 mm using a hammermill-type crusher, thereby manufacturing an artificial chip having the texture of natural granite.
  • Example 1 800 parts by weight of the artificial chip having the texture of natural granite prepared in Example 1 was mixed with a base resin containing 150 parts by weight of an acrylic resin, 6 parts by weight of pearl, 1 part by weight of a curing agent, and 5 parts by weight of additives.
  • the mixture was heat-pressed at 100° C. and at about 50 Kgf/m 2 to manufacture artificial marble in a plate shape.
  • Results are shown in FIGS. 4 and 5 .

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Civil Engineering (AREA)
  • Compositions Of Macromolecular Compounds (AREA)
  • Processes Of Treating Macromolecular Substances (AREA)
US13/144,497 2009-01-16 2010-01-14 Artificial chip having the texture of natural granite and artificial marble including the same Abandoned US20110275737A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
KR10-2009-0003859 2009-01-16
KR1020090003859A KR20100084391A (ko) 2009-01-16 2009-01-16 천연화강석 질감을 갖는 칩인칩 및 이를 이용한 인조대리석
PCT/KR2010/000227 WO2010082767A2 (ko) 2009-01-16 2010-01-14 천연화강석 질감을 갖는 인조칩 및 이를 포함하는 인조대리석

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US (1) US20110275737A1 (ko)
EP (1) EP2388241A4 (ko)
JP (1) JP5829124B2 (ko)
KR (1) KR20100084391A (ko)
CN (1) CN102272069A (ko)
WO (1) WO2010082767A2 (ko)

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US9469745B2 (en) 2012-10-25 2016-10-18 Kohler Co Engineered composite material and products produced therefrom
WO2020138604A1 (ko) * 2018-12-27 2020-07-02 롯데케미칼 주식회사 인조 대리석
CN111393073A (zh) * 2020-04-21 2020-07-10 广东传奇岗石有限公司 一种网状花纹玫瑰黑人造大理石制备工艺

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KR101354654B1 (ko) * 2012-12-11 2014-01-23 (주)하나소재 인조대리석분말을 이용한 인조대리석의 재활용 칩의 제조방법 및 이로 제조되는 인조대리석의 재활용 칩을 포함하는 인조대리석
KR101596545B1 (ko) * 2013-01-31 2016-02-22 제일모직주식회사 다색층을 가지는 강화천연석용 칩 조성물 및 이를 포함하는 강화천연석
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WO2015160011A1 (ko) * 2014-04-17 2015-10-22 월드씨엠엠에이(주) 원두커피 분말 및 커피부산물을 이용한 커피향이 나는 환경친화적 인조대리석 및 그 제조방법
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CN107244120A (zh) * 2017-06-20 2017-10-13 合肥慧林建材有限公司 一种新型大理石道路板材及制备方法
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KR102250434B1 (ko) * 2018-10-23 2021-05-10 롯데첨단소재(주) 강화 천연석
JP2023503032A (ja) * 2019-11-20 2023-01-26 コベストロ・インテレクチュアル・プロパティ・ゲゼルシャフト・ミット・ベシュレンクテル・ハフツング・アンド・コー・カーゲー 繊維強化熱可塑性複合材シート及びそれを作製する方法
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WO2010082767A9 (ko) 2010-10-21
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WO2010082767A3 (ko) 2010-12-09

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